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NASA NTRS1993

Development and testing of 11- and 24-inch hybrid motors under the joint government/industry IR&D program

Establishment of a test facility and associated 11-in.-diameter motor for hybrid propulsion technology development at NASA's George C. Marshall Space Flight Center is discussed in this paper. Results of twenty 11-in.-diameter motor tests with a UTF-29901 (60 percent polycyclopentadiene, 40 percent hydroxyl-terminated polybutadiene)/gaseous oxygen propellant system are presented. Tests at this scale have developed fuel regression correlations for comparison with results of yet-to-be-completed, 24-in.-diameter motor tests; demonstrated combustion efficiency levels in the 95 percent range for both single- and multiple-port grain configurations; have shown smooth and stable throttling characteristics over flight-type throttle ranges; and have begun to establish criteria for stable combustion in hybrid motors. The testing of 24-in. motors has not as yet been initiated and is not addressed.

Boardman, T. A.↗

NASA NTRS1993

Performance-seeking control - Program overview and future directions

A flight test evaluation of the performance-seeking control (PSC) algorithm on the NASA F-15 highly integrated digital electronic control research aircraft was conducted for single-engine operation at subsonic and supersonic speeds. The model-based PSC system was developed with three optimization modes: minimum fuel flow at constant thrust, minimum turbine temperature at constant thrust, and maximum thrust at maximum dry and full afterburner throttle settings. Subsonic and supersonic flight testing were conducted at the NASA Dryden Flight Research Facility covering the three PSC optimization modes and over the full throttle range. Flight results show substantial benefits. In the maximum thrust mode, thrust increased up to 15 percent at subsonic and 10 percent at supersonic flight conditions. The minimum fan turbine inlet temperature mode reduced temperatures by more than 100 F at high altitudes. The minimum fuel flow mode results decreased fuel consumption up to 2 percent in the subsonic regime and almost 10 percent supersonically. These results demonstrate that PSC technology can benefit the next generation of fighter or transport aircraft.

Gilyard, Glenn B.↗

NASA NTRS1920

Investigation of the Muffling Problem for Airplane Engines

The experimentation presented in this report falls in two divisions: first, the determination of the relation between back pressure in the exhaust line and consequent power loss, for various combinations of speed and throttle positions of the engine; second, the construction and trial of muffler designs covering both type and size. Report deals with experiments in the development of a muffler designed on the principle which will give the maximum muffling effect with a minimum loss of power. The main body of the work has been done on a Curtiss OX eight-cylinder airplane engine, 4 by 5 inches, rated 70 horsepower at 1,200 revolutions per minute. For estimation of the muffling ability and suppression of "bark" of individual exhausts, the "Ingeco" stationary, single cylinder, 5 1/2 by 10 inch, throttling governed gasoline engine, and occasionally other engines were used.

Upton, G B↗

NASA NTRS1928

The relative performance obtained with several methods of control of an overcompressed engine using gasoline

This report presents some results obtained during an investigation to determine the relative characteristics for several methods of control of an overcompressed engine using gasoline and operating under sea-level conditions. For this work, a special single cylinder test engine, 5-inch bore by 7-inch stroke, and designed for ready adjustment of compression ratio, valve timing and valve lift while running, was used. This engine has been fully described in NACA-TR-250. Tests were made at an engine speed of 1,400 R. P. M. for compression ratios ranging from 4.0 to 7.6. The air-fuel ratios were on the rich side of the chemically correct mixture and were approximately those giving maximum power. When using plain domestic gasoline, detonation was controlled to a constant, predetermined amount (audible), such as would be permissible for continuous operation, by (a) throttling the carburetor, (b) maintaining full throttle but greatly retarding the ignition, and (c) varying the timing of the inlet valve to reduce the effective compression ratio. From the results of the tests, it may be concluded that method (b) gives the best all-round performance and, being easily employed in service, appears to be the most practicable method for controlling an overcompressed engine using gasoline at low altitudes.

Gardiner, Arthur W↗

NASA NTRS1936

Distribution and regularity of injection from a multicylinder fuel-injection pump

This report presents the results of performance test conducted on a six-cylinder commercial fuel-injection pump that was adjusted to give uniform fuel distribution among the cylinders at a throttle setting of 0.00038 pound per injection and a pump speed of 750 revolutions per minute. The throttle setting and pump speed were then varied through the operating range to determine the uniformity of distribution and regularity of injection.

Rothrock, A M↗

NASA NTRS1937

Flight Tests of the Drag and Torque of the Propeller in Terminal-Velocity Dives

The drag and torque of a controllable propeller at various blade-angle settings, and under various diving conditions, were measured by indirect method on F6C-4 airplane in flight. The object of these tests were (1) to provide data on which calculations of the terminal velocity with a throttled engine and the accompanying engine speed could be based and (2) to determine the possibility of utilizing the propeller as an air brake to reduce the terminal velocity. The data obtained were used in the establishment of propeller charts, on the basis of which the terminal velocity and engine speed could be calculated for airplanes whose characteristics fall within the range of these tests. A method is given for the calculation of the terminal velocity with throttled engine and the engine speed.

Rhode, Ricahrd V↗

NASA NTRS1940

Standards for discharge measurement with standardized nozzles and orifices

The following standards give the standardized forms for two throttling devices, standard nozzles and standard orifices, and enable them to be used in circular pipes without calibration. The definition of the standards are applicable in principle to the calibration and use of nonstandardized throttling devices, such as the venturi tube. The standards are valid, likewise, as a basis for discharge measurements in the German acceptance standards.

Source record↗

NASA NTRS1938

Flow in Smooth Straight Pipes at Velocities Above and Below Sound Velocity

To investigate the laws of flow of compressible fluids in pipes, tests were carried out with air flowing at velocities below and above that of sound in straight smooth pipes. Air was chosen as the flow medium. In order that the effect of compressibility may be brought out most effectively, the velocity should lie between 100 and 500 m/s (200 and 1,000 mph); that is, be of the order of magnitude of the velocity of sound in air. The behavior of the compression shock in a smooth cylindrical pipe was also investigated. The compression shock can occur at any position in the pipe, depending on the throttling downstream, and travels upstream with increasing throttling up to the pipe entrance, so that only subsonic velocities occur in the pipe.

Frossel, W↗

NASA NTRS1934

Influence of Cut-outs in Elevator on the Static Longitudinal Stability and on the Static Elevator Effect

The rudder effect of a sport airplane at high angles of attack was to be improved. This made it necessary to make a cut-out in the center of the continuous elevator so as to enlarge the rudder downward. This cut-out which reduced the rudder area by 12.5 percent changed the static stability of the airplane as well as the elevator effect. Flight measurements showed the stability zone with locked elevator to be 1.8 percent less at full throttle and at idling to be 1.3 percent less than the mean wing chord. The effect of the cut-out on the control forces could not be determined owing to insufficient instrumental accuracy at the extremely low existing forces. The measurement of the static controllability resulting from the cut-out manifested an 18 percent drop in elevator effect at full throttle and a 10 to 20 percent drop at idling, depending on lift.

Biechteler, Curt↗

NASA NTRS1993

Performance seeking control: Program overview and future directions

Gilyard, Glenn B.↗

NASA NTRS1993

Inherent stability of central element coaxial liquid-liquid injectors

Most TRW liquid bi-propellant rocket engines built over the past thirty-plus years have employed a central element coaxial pintle injector and have operated with liquid/liquid propellant injection. This injector is a patented design exclusive to TRW and has unique features that make the rocket engine combustion characteristics different from those of other types of injector engine designs. Its many benefits include excellent combustion performance, efficient deep throttling, adaptability to low cost manufacturing, and high reliability. Approximately 200 pintle injector engines of various sizes and operating on a variety of propellants have been flown without a single inflight failure. An especially important feature of the pintle injector engine is its apparent inherent combustion stability. In over thirty years of development, testing, and production, TRW has never experienced combustion instability in any of its pintle injector engine designs. This has been true of engines operating over a range of thrust from 5 to 250,000 lbs. on earth-storable hypergolic propellants and a large number of smaller engines operating on a variety of propellants (21 combinations) in long duration-firing, pulsing (down to 2 msec), and deep throttling (as much as 19:1) modes. Operating chamber pressures have ranged from 10 to 3,500 psia. This record is particularly impressive given that typical TRW design practice does not consider combustion instability as an issue and no pintle engine has ever employed stability-enhancing features, such as baffles or acoustically resonant chambers. In spite of this, TRW engines have operated stably in regimes not possible with other types of injectors. Various physical explanations and combustion process models for this favorable stability characteristic have been postulated. However, a definitive study that unequivocally establishes the important stabilizing mechanisms still remains to be conducted.

Stoddard, Frank J.↗

NASA NTRS1994

The 7.5K lbf thrust engine preliminary design for Orbit Transfer Vehicle

This document summarizes the preliminary design of the Aerojet version of the Orbit Transfer Vehicle main engine. The concept of a 7500 lbf thrust LO2/GH2 engine using the dual expander cycle for optimum efficiency is validated through power balance and thermal calculations. The engine is capable of 10:1 throttling from a nominal 2000 psia to a 200 psia chamber pressure. Reservations are detailed on the feasibility of a tank head start, but the design incorporates low speed turbopumps to mitigate the problem. The mechanically separate high speed turbopumps use hydrostatic bearings to meet engine life requirements, and operate at sub-critical speed for better throttling ability. All components were successfully packaged in the restricted envelope set by the clearances for the extendible/retractable nozzle. Gimbal design uses an innovative primary and engine out gimbal system to meet the +/- 20 deg gimbal requirement. The hydrogen regenerator and LOX/GH2 heat exchanger uses the Aerojet platelet structures approach for a highly compact component design. The extendible/retractable nozzle assembly uses an electric motor driven jack-screw design and a one segment carbon-carbon or silicide coated columbium nozzle with an area ratio, when extended, of 1430:1. A reliability analysis and risk assessment concludes the report.

Hayden, Warren R.↗

NASA NTRS1995

Automated Propulsion Data Screening demonstration system

A fully-instrumented firing of a propulsion system typically generates a very large quantity of data. In the case of the Space Shuttle Main Engine (SSME), data analysis from ground tests and flights is currently a labor-intensive process. Human experts spend a great deal of time examining the large volume of sensor data generated by each engine firing. These experts look for any anomalies in the data which might indicate engine conditions warranting further investigation. The contract effort was to develop a 'first-cut' screening system for application to SSME engine firings that would identify the relatively small volume of data which is unusual or anomalous in some way. With such a system, limited and expensive human resources could focus on this small volume of unusual data for thorough analysis. The overall project objective was to develop a fully operational Automated Propulsion Data Screening (APDS) system with the capability of detecting significant trends and anomalies in transient and steady-state data. However, the effort limited screening of transient data to ground test data for throttle-down cases typical of the 3-g acceleration, and for engine throttling required to reach the maximum dynamic pressure limits imposed on the Space Shuttle. This APDS is based on neural networks designed to detect anomalies in propulsion system data that are not part of the data used for neural network training. The delivered system allows engineers to build their own screening sets for application to completed or planned firings of the SSME. ERC developers also built some generic screening sets that NASA engineers could apply immediately to their data analysis efforts.

Hoyt, W. Andes↗

NASA NTRS1995

Propulsion Controlled Aircraft design and development

This paper describes the design, development, and ground testing of the propulsion controlled aircraft (PCA) flight control system. A backup flight control system which uses only engine thrust, the PCA system utilizes collective and differential thrust changes to steer an aircraft that experiences partial or complete failure of the hydraulically actuated control surfaces. The objective of the program was to investigate, in flight, the throttles-only control capability of the F-15, using manual control, and also an augmented PCA mode in which computer-controlled thrust was used for flight control. The objective included PCA operation in up-and-away flight and, if performance was adequate, a secondary objective to make actual PCA landings. The PCA design began with a feasibility study which evaluated many control law designs. The study was done using off-line control analysis, simulation, and on-line manned flight simulator tests. Control laws, cockpit displays, and cockpit controls were evaluated by NASA test pilots. A flight test baseline configuration was selected based on projected flight performance, applicability to transport and fighter aircraft, and funding costs. During the PCA software and hardware development, the initial design was updated as data became available from throttle-only flight experiments conducted by NASA on the F-15. This information showed basic airframe characteristics that were not observed in the F-15 flight simulator and resulted in several design changes. After the primary objectives of the PCA flight testing were accomplished, additional PCA modes of operation were developed and implemented. The evolution of the PCA system from the initial feasibility study, control law design, simulation, hardware-in-the-loop tests, pilot-in-the-loop tests, and ground tests is presented.

Wells, Edward A.↗

NASA NTRS1995

Flight test of a propulsion controlled aircraft system on the NASA F-15 airplane

Flight tests of the propulsion controlled aircraft (PCA) system on the NASA F-15 airplane evolved as a result of a long series of simulation and flight tests. Initially, the simulation results were very optimistic. Early flight tests showed that manual throttles-only control was much more difficult than the simulation, and a flight investigation was flown to acquire data to resolve this discrepancy. The PCA system designed and developed by MDA evolved as these discrepancies were found and resolved, requiring redesign of the PCA software and modification of the flight test plan. Small throttle step inputs were flown to provide data for analysis, simulation update, and control logic modification. The PCA flight tests quickly revealed less than desired performance, but the extensive flexibility built into the flight PCA software allowed rapid evaluation of alternate gains, filters, and control logic, and within 2 weeks, the PCA system was functioning well. The initial objective of achieving adequate control for up-and-away flying and approaches was satisfied, and the option to continue to actual landings was achieved. After the PCA landings were accomplished, other PCA features were added, and additional maneuvers beyond those originally planned were flown. The PCA system was used to recover from extreme upset conditions, descend, and make approaches to landing. A heading mode was added, and a single engine plus rudder PCA mode was also added and flown. The PCA flight envelope was expanded far beyond that originally designed for. Guest pilots from the USAF, USN, NASA, and the contractor also flew the PCA system and were favorably impressed.

Burcham, Frank W., Jr.↗

NASA NTRS1995

A concept for adaptive performance optimization on commercial transport aircraft

An adaptive control method is presented for the minimization of drag during flight for transport aircraft. The minimization of drag is achieved by taking advantage of the redundant control capability available in the pitch axis, with the horizontal tail used as the primary surface and symmetric deflection of the ailerons and cruise flaps used as additional controls. The additional control surfaces are excited with sinusoidal signals, while the altitude and velocity loops are closed with guidance and control laws. A model of the throttle response as a function of the additional control surfaces is formulated and the parameters in the model are estimated from the sensor measurements using a least squares estimation method. The estimated model is used to determine the minimum drag positions of the control surfaces. The method is presented for the optimization of one and two additional control surfaces. The adaptive control method is extended to optimize rate of climb with the throttle fixed. Simulations that include realistic disturbances are presented, as well as the results of a Monte Carlo simulation analysis that shows the effects of changing the disturbance environment and the excitation signal parameters.

Jackson, Michael R.↗

NASA NTRS1996

Assessment of Lifting Body Linear Aerospike Plume Effects on Vehicle Aerodynamics

The lifting body/linear aerospike is one of three configurations being studied for a single stage to orbit (SSTO) vehicle. A preliminary aerodynamics database existed for then current lifting body configurations, however, this database was developed without considering plume effects. A combined effort by the Computational Fluid Dynamics (CFD) and the Experimental Fluids Dynamics Branches was undertaken to determine first order effects of plume/external flow interactions on vehicle aerodynamics of this lifting body/linear aerospike configuration. Of interest were plume pumping/entrainment at low Mach numbers and plume induced separation of flow over the vehicle at higher altitudes. The CFD analysis included combinations of four Mach numbers, two angles of attack, and four throttle settings. The majority of the CFD was two dimensional centerline analysis of the lifting body/aerospike. Incremental plume effects were derived by comparing the power-on, power-off, and throttled cases and were extrapolated to the preliminary aerodynamic database. The plume had little effect on the vehicle aerodynamics for supersonic freestream velocities. At subsonic freestream velocities, the plume affected the vehicle aerodynamics through both jet pumping/entrainment and the jet flap effect.

Ruf, Joseph H.↗

NASA NTRS1996

Development and Flight Test of an Augmented Thrust-Only Flight Control System on an MD-11 Transport Airplane

An emergency flight control system using only engine thrust, called Propulsion-Controlled Aircraft (PCA), has been developed and flight tested on an MD-11 airplane. In this thrust-only control system, pilot flight path and track commands and aircraft feedback parameters are used to control the throttles. The PCA system was installed on the MD-11 airplane using software modifications to existing computers. Flight test results show that the PCA system can be used to fly to an airport and safely land a transport airplane with an inoperative flight control system. In up-and-away operation, the PCA system served as an acceptable autopilot capable of extended flight over a range of speeds and altitudes. The PCA approaches, go-arounds, and three landings without the use of any non-nal flight controls have been demonstrated, including instrument landing system-coupled hands-off landings. The PCA operation was used to recover from an upset condition. In addition, PCA was tested at altitude with all three hydraulic systems turned off. This paper reviews the principles of throttles-only flight control; describes the MD-11 airplane and systems; and discusses PCA system development, operation, flight testing, and pilot comments.

Burcham, Frank W., Jr.↗